ALUMINUM SECONDARY BATTERY HAVING A HIGH-CAPACITY AND HIGH ENERGY CATHODE AND MANUFACTURING METHOD

CROSS REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Patent Application No. 15/431,250, filed on February 13, 2017, which is hereby incorporated by reference. FIELD OF THE INVENTION

The present invention relates generally to the field of rechargeable aluminum battery and, more particularly, to a high-capacity cathode layer containing a new group of graphite or carbon materials having expanded inter-planar spaces and a method of manufacturing this cathode layer and the aluminum battery. BACKGROUND OF THE INVENTION

Historically, today's most favorite rechargeable energy storage devices - lithium-ion batteries - was actually evolved from rechargeable "lithium metal batteries" that use lithium (Li) metal as the anode and a Li intercalation compound (e.g. MoS ₂ ) as the cathode. Li metal is an ideal anode material due to its light weight (the lightest metal), high electronegativity (-3.04 V vs. the standard hydrogen electrode), and high theoretical capacity (3,860 mAh/g). Based on these outstanding properties, lithium metal batteries were proposed 40 years ago as an ideal system for high energy-density applications.

Due to some safety concerns of pure lithium metal, graphite was implemented as an anode active material in place of the lithium metal to produce the current lithium-ion batteries. The past two decades have witnessed a continuous improvement in Li-ion batteries in terms of energy density, rate capability, and safety. However, the use of graphite-based anodes in Li-ion batteries has several significant drawbacks: low specific capacity (theoretical capacity of 372 mAh/g as opposed to 3,860 mAh/g for Li metal), long Li intercalation time (e.g. low solid-state diffusion coefficients of Li in and out of graphite and inorganic oxide particles) requiring long recharge times (e.g. 7 hours for electric vehicle batteries), inability to deliver high pulse power, and necessity to use prelithiated cathodes (e.g. lithium cobalt oxide, as opposed to cobalt oxide), thereby limiting the choice of available cathode materials. Further, these commonly used cathode active materials have a relatively low lithium diffusion coefficient (typically D ~ 10 ^"16 - 10 ^"11 cm ² /sec). These factors have contributed to one major shortcoming of today's Li-ion batteries - a moderate energy density (typically 150-220 Wh/kg _ce n), but extremely low power density

(typically < 0.5 kW/kg). Supercapacitors are being considered for electric vehicle (EV), renewable energy storage, and modern grid applications. The relatively high volumetric capacitance density of a

supercapacitor (10 to 100 times greater than those of electrolytic capacitors) derives from using porous electrodes to create a large surface area conducive to the formation of diffuse double layer charges. This electric double layer capacitance (EDLC) is created naturally at the solid- electrolyte interface when voltage is imposed. This implies that the specific capacitance of a supercapacitor is directly proportional to the specific surface area of the electrode material, e.g. activated carbon. This surface area must be accessible by the electrolyte and the resulting interfacial zones must be sufficiently large to accommodate the EDLC charges.

This EDLC mechanism is based on surface ion adsorption. The required ions are pre- existing in a liquid electrolyte and do not come from the opposite electrode. In other words, the required ions to be deposited on the surface of a negative electrode (anode) active material (e.g., activated carbon particles) do not come from the positive electrode (cathode) side, and the required ions to be deposited on the surface of a cathode active material do not come from the anode side. When a supercapacitor is re-charged, local positive ions are deposited close to a surface of a negative electrode with their matting negative ions staying close side by side

(typically via local molecular or ionic polarization of charges). At the other electrode, negative ions are deposited close to a surface of this positive electrode with the matting positive ions staying close side by side. Again, there is no exchange of ions between an anode active material and a cathode active material. In some supercapacitors, the stored energy is further augmented by pseudo-capacitance effects due to some local electrochemical reactions (e.g., redox). In such a pseudo-capacitor, the ions involved in a redox pair also pre-exist in the same electrode. Again, there is no exchange of ions between the anode and the cathode. Since the formation of EDLC does not involve a chemical reaction or an exchange of ions between the two opposite electrodes, the charge or discharge process of an EDL

supercapacitor can be very fast, typically in seconds, resulting in a very high power density (typically 3-10 kW/kg). Compared with batteries, supercapacitors offer a higher power density, require no maintenance, offer a much higher cycle-life, require a very simple charging circuit, and are generally much safer. Physical, rather than chemical, energy storage is the key reason for their safe operation and extraordinarily high cycle-life.

Despite the positive attributes of supercapacitors, there are several technological barriers to widespread implementation of supercapacitors for various industrial applications. For instance, supercapacitors possess very low energy densities when compared to batteries (e.g., 5-8 Wh/kg for commercial supercapacitors vs. 10-30 Wh/kg for the lead acid battery and 50-100 Wh/kg for the NiMH battery). Modern lithium-ion batteries possess a much higher energy density, typically in the range of 150-220 Wh/kg, based on the cell weight.

Secondary batteries based on various charge-discharge principles other than lithium ions have been proposed. Among them, some attention has been paid to aluminum secondary batteries based on the deposition-dissolution reaction of aluminum (Al) at the anode. Aluminum has a high ionization tendency and is capable of three-electron redox reactions, which can potentially enable an aluminum battery to deliver to a high capacity and high energy density.

The abundance, low cost, and low flammability of Al, and its ability to undergo three- electron redox imply that rechargeable Al-based batteries could in principle offer cost- effectiveness, high capacity and safety. However, the rechargeable Al batteries developed over the past 30 years have failed to make it to the marketplace. This has been likely due to problems such as cathode material disintegration, low cell discharge voltage (e.g. 0.55V), a capacitive behavior without a discharge voltage plateau (e.g.1.1-0.2 V), and short cycle life (typically < 100 cycles) with rapid capacity decay (by 26-85% over 100 cycles), low cathode specific capacity, and low cell-level energy density (< 50 Wh/kg).

For instance, Jayaprakash reports an aluminum secondary battery that shows a discharge curve having a plateau at 0.55 V [Jayaprakash, N., Das, S. K. & Archer, L. A. "The rechargeable aluminum-ion battery," Chem. Commun. 47, 12610-12612 (2011)]. A rechargeable battery having an output voltage lower than 1.0 volt has a limited scope of application. As a point of reference, alkaline battery has an output voltage of 1.5 volts and a lithium-ion battery has a typical cell voltage of 3.2-3.8 volts. Furthermore, even with an initial cathode specific capacity as high as 305 mAh/g, the energy storage capability of the cathode is approximately 0.55 V x 305 mAh/g = 167.75 Wh/kg based on the cathode active material weight alone (not based on the total cell weight). Thus, the cell-level specific energy (or gravimetric energy density) of this Al- V ₂ 0 ₅ cell is approximately 167.75/3.6 = 46.6 Wh/kg (based on the total cell weight).

(As a point of reference, a lithium-ion battery having a lithium iron phosphate (LFP) as the cathode active material (having a theoretical specific capacity of 170 mAh/g) delivers an output voltage of 3.2 volts and an energy storage capability of 3.2 V x 170 mAh/g = 544 Wh/kg (based on the LFP weight only). This cell is known to deliver a cell-level energy density of approximately 150 Wh/kg. There is a reduction factor of 544/150 = 3.6 to convert a cathode active material weight-based energy density value to a total cell weight-based energy density value in this battery system.) As another example, Rani reports an aluminum secondary battery using a lightly fluorinated natural graphite as the cathode active material having an output voltage varying from 0.2 volts to 1.1 volts [Rani, J. V., Kanakaiah, V., Dadmal, T., Rao, M. S. & Bhavanarushi, S. "Fluorinated natural graphite cathode for rechargeable ionic liquid based aluminum-ion battery," J. Electrochem. Soc. 160, A1781-A1784 (2013)]. With an average voltage of approximately 0.65 volts and a discharge capacity of 225 mAh/g, the cell delivers an energy storage capability of 0.65 x 225 = 146.25 Wh/kg (of the cathode active material weight only) or cell-level specific energy of 146.25/3.6 = 40.6 Wh/kg (based on the total cell weight). As yet another example, Lin, et al. reports an aluminum-graphite foam cell that exhibits a plateau voltage near 2 volts and an output voltage of 70 mAh/g [Lin MC, Gong M, Lu B, Wu Y, Wang DY, Guan M, Angell M, Chen C, Yang J, Hwang BJ, Dai H., "An ultrafast rechargeable aluminum-ion battery," Nature. 2015 Apr 16;520 (7547):325-8]. The cell-level specific energy is expected to be approximately 70 x 2.0/3.6 = 38.9 Wh/kg. As a matter of fact, Lin, et al. has confirmed that the specific energy of their cell is approximately 40 Wh/kg.

Clearly, an urgent need exists for new cathode materials that provide proper discharge voltage profiles (having a high average voltage and/or a high plateau voltage during discharge), high specific capacity at both high and low charge/discharge rates (not just at a low rate), and long cycle-life for an aluminum secondary battery. Hopefully, the resulting aluminum battery can deliver some positive attributes of a supercapacitor (e.g. long cycle life and high power density) and some positive features of a lithium-ion battery (e.g. moderate energy density). These are the main objectives of the instant invention.

SUMMARY OF THE INVENTION The invention provides a cathode or positive electrode layer for an aluminum secondary battery (rechargeable aluminum battery or aluminum-ion battery) and an aluminum secondary battery containing such a cathode layer.

In some preferred embodiments, the invented aluminum secondary battery comprises an anode, a cathode, and an electrolyte in ionic contact with the anode and the cathode to support reversible deposition and dissolution of aluminum at the anode, wherein the anode contains aluminum metal or an aluminum metal alloy and the cathode comprises a cathode active layer of a graphite or carbon material having expanded inter-graphene planar spaces with an inter-planar spacing d ₀ 02 from 0.43 nm to 2.0 nm as measured by X-ray diffraction and an optional 0-30% by weight of a conductive additive based on a total weight of the cathode active layer, wherein the conductive additive is selected from a carbon or graphite material having un-expanded inter- graphene planar spaces with an inter-planar spacing doo ₂ from 0.33 nm to 0.36 nm. Preferably, the electrolyte also supports reversible intercalation and de-intercalation of ions (cations, anions, or both) at the cathode. The aluminum alloy preferably contains at least 80% by weight Al element in the alloy (more preferably at least 90% by weight). There is no restriction on the type of alloying elements that can be chosen. Preferably, the alloying elements for Al are Si, B, Mg, Ti, Sc, etc.

This conductive graphite additive is the original natural graphite or synthetic graphite that has an inter-planar spacing doo ₂ from 0.33 nm to 0.36 nm (e.g. the graphite that has never been exposed to an expansion treatment). The inter-planar spacing doo ₂ of natural graphite is approximately 0.3354 nm and that of synthetic graphite is most typically from 0.33 nm to 0.36 nm. The proportion of this conductive additive in the cathode active layer is preferably less than 20%) by weight, more preferably less than 10%> by weight, and most preferably less than 5% by weight.

This aluminum secondary battery can further comprise an anode current collector supporting the aluminum metal or aluminum metal alloy or further comprise a cathode current collector supporting the cathode active layer. The current collector can be a mat, paper, fabric, foil, or foam that is composed of conducting nanofilaments, such as graphene sheets, carbon nanotubes, carbon nanofibers, carbon fibers, graphite nanofibers, graphite fibers, carbonized polymer fibers, or a combination thereof, which form a 3D network of electron-conducting pathways. The high surface areas of such an anode current collector not only facilitate fast and uniform dissolution and deposition of aluminum ions, but also act to reduce the exchange current density and, thus, the tendency to form metal dendrites that otherwise could cause internal shorting.

The carbon or graphite material having expanded inter-planar spaces is selected from mesophase pitch, mesophase carbon, mesocarbon microbeads (MCMB), coke particles, expanded graphite flakes, artificial graphite particles, natural graphite particles, highly oriented pyrolytic graphite, soft carbon particles, hard carbon particles, multi-walled carbon nanotubes, carbon nanofibers, carbon fibers, graphite nanofibers, graphite fibers, carbonized polymer fibers, or a combination thereof, wherein the carbon or graphite material has an inter-planar spacing doo ₂ from 0.27 nm to 0.42 nm prior to a chemical or physical expansion treatment and the inter-planar spacing d ₀ 02-is increased to from 0.43 nm to 2.0 nm after the expansion treatment. The expansion treatment includes an expansion treatment includes an oxidation, fluorination, bromination, chlorination, nitrogenation, intercalation, combined oxidation- intercalation, combined fluorination-intercalation, combined bromination-intercalation, combined chlorination-intercalation, or combined nitrogenation-intercalation of the graphite or carbon material. The above procedure may be followed by a constrained thermal expansion treatment.

In certain embodiments, the carbon or graphite material having expanded inter-planar spaces is selected from graphite foam or graphene foam having pores and pore walls, wherein the pore walls contain a stack of bonded graphene planes having an expanded inter-planar spacing doo2 from 0.45 nm to 1.5 nm. Preferably, the stack contains from 2 to 100 graphene planes (hexagonal carbon atom planes).

In certain embodiments, the inter-planar spacing d ₀ 02 of the carbon or graphite material is from 0.5 nm to 1.2 nm. In other embodiments, the inter-planar spacing, doo ₂ , is from 1.2 nm to 2.0 nm. Due to the expansion treatments, the carbon or graphite material can contain a non- carbon element selected from oxygen, fluorine, chlorine, bromine, iodine, nitrogen, hydrogen, or boron.

In the invented aluminum secondary battery, the electrolyte may be selected from an aqueous electrolyte, organic electrolyte, molten salt electrolyte, or ionic liquid electrolyte. A polymer may be added to the electrolyte. Preferably, the electrolyte contains an aluminum salt such as, A1F ₃ , A1C1 ₃ , AlBr ₃ , A1I ₃ , A1F _X C1 _(3-X) , AlBr _x Cl _(3-x) , A1I _X C1 _(3-X) , or a combination thereof, wherein x is from 0.01 to 2.0. Mixed aluminum halides, such as A1F _X C1( _3-X ), AlBr _x Cl( _3-X ), A1I _X C1( ₃ . x ₎ , can be readily produced by brominating, fluorinating, or iodizing A1C1 ₃ to a desired extent; for instance at 100-350°C for 1-24 hours.. Preferably, the electrolyte contains an ionic liquid that contains an aluminum salt mixed with an organic chloride selected from n-butyl-pyridinium-chloride (BuPyCl), l-methyl-3- ethylimidazolium-chloride (MEIC1), 2-dimethyl-3-propylimidazolium-chloride, 1,4-dimethyl- 1,2,4-triazolium chloride (DMTC), or a mixture thereof. In certain embodiments, the layer of carbon or graphite material operates as a cathode current collector to collect electrons during a discharge of the aluminum secondary battery and wherein the battery contains no separate or additional cathode current collector.

The cathode active layer of graphite may further comprise an electrically conductive binder material which bonds particles or fibers of the carbon or graphite material together to form a cathode electrode layer. The electrically conductive binder material may be selected from coal tar pitch, petroleum pitch, mesophase pitch, a conducting polymer, a polymeric carbon, or a derivative thereof.

Typically, the invented aluminum secondary battery has an average discharge voltage no less than 1 volt (typically and preferably > 1.5 volts) and a cathode specific capacity greater than 200 mAh/g (preferably and more typically > 300 mAh/g, more preferably > 400 mAh/g, and most preferably > 500 mAh/g) based on a total cathode active layer weight.

Preferably, the aluminum secondary battery has an average discharge voltage no less than 2.0 volts and a cathode specific capacity greater than 100 mAh/g based on a total cathode active layer weight (preferably and more typically > 300 mAh/g, more preferably > 400 mAh/g, and most preferably > 500 mAh/g).

The present invention also provides a cathode active layer for an aluminum secondary battery. The cathode active layer comprises a graphite or carbon material having expanded inter- graphene planar spaces with an inter-planar spacing d ₀ 02 from 0.43 nm to 2.0 nm as measured by X-ray diffraction, wherein said cathode layer comprises less than 30% by weight of an original graphite having no expanded inter-graphene planar spaces and having an inter-planar spacing doo2 from 0.334 nm to 0.34 nm. Preferably, the carbon or graphite material is selected from mesophase pitch, mesophase carbon, mesocarbon microbeads (MCMB), coke particles, expanded graphite flakes, artificial graphite particles, natural graphite particles, highly oriented pyrolytic graphite, soft carbon particles, hard carbon particles, multi-walled carbon nanotubes, carbon nanofibers, carbon fibers, graphite nanofibers, graphite fibers, carbonized polymer fibers, carbon aerogel, carbon xerogel or a combination thereof, wherein the carbon or graphite material has an inter-planar spacing d ₀ 02 from 0.27 nm to 0.42 nm prior to a chemical or physical expansion treatment and the inter-planar spacing doo ₂ is increased to from 0.43 nm to 2.0 nm after the expansion treatment.

In certain preferred embodiments, the carbon or graphite material is selected from graphite foam or graphene foam having pores and pore walls, wherein the pore walls contain a stack of bonded graphene planes having an expanded inter-planar spacing doo ₂ from 0.45 nm to 1.5 nm. Preferably, the stack contains from 2 to 100 graphene planes (more preferably from 2 to 20 graphene planes).

The present invention also provides a method of manufacturing an aluminum secondary battery. The methods comprises: (a) providing an anode containing aluminum or an aluminum alloy; (b) providing a cathode containing a carbon or graphite material having expanded inter- planar spaces, d ₀ 02 from 0.43 nm to 2.0 nm; and (c) providing an electrolyte capable of supporting reversible deposition and dissolution of aluminum at the anode and reversible adsorption/desorption and/or intercalation/de-intercalation of ions at the cathode. Preferably, the electrolyte contains an aqueous electrolyte, an organic electrolyte, a molten salt electrolyte, or an ionic liquid

The method can further include providing a porous network of electrically conductive nanofilaments to support said aluminum or aluminum alloy.

In some preferred embodiments, the carbon or graphite material contains a graphite foam or graphene foam having pore walls composed of multiple graphene planes having inter-planar spacing from 0.43 nm to 2.0 nm.

The step of providing a cathode preferably contains subjecting a carbon or graphite material to an expansion treatment selected from oxidation, fluorination, bromination, chlorination, nitrogenation, intercalation, combined oxidation-intercalation, combined fluorination-intercalation, combined bromination-intercalation, combined chlorination- intercalation, or combined nitrogenation-intercalation.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1(A) Schematic drawing illustrating the processes for producing intercalated and/or oxidized graphite, subsequently exfoliated graphite worms, and conventional paper, mat, film, and membrane of simply aggregated graphite or graphene flakes/platelets;

FIG. 1(B) An SEM image of graphite worms;

FIG. 1(C) Another SEM image of graphite worms;

FIG. 1(D) Schematic drawing illustrating the approaches of producing graphite structures

containing expanded inter-planar spaces.

FIG. 2(A) Schematic of an aluminum secondary battery, wherein the anode layer is a thin Al coating or Al foil and the cathode active material layer contains a layer of graphite foam or graphene foam wherein the pore walls contain multiple hexagonal carbon atom planes bonded together having expanded inter-planar spaces (d ₀ 02 = 0.4 nm to 2.0 nm); and

FIG. 2(B) schematic of an aluminum secondary battery cell; the cathode active material layer being composed of particles or fibers of a graphite or carbon material (having expanded inter-planar spaces), a conductive additive (not shown) and a resin binder (not shown).

FIG. 3 The charge and discharge curves of two Al foil anode-based cells that each has a graphite foam-based cathode (one with expanded inter-planar spaces and one without).

FIG. 4 The specific capacity values of a wide variety of carbon or graphite materials plotted as a function of the inter-planar spacing.

FIG. 5 The specific capacity of a cell containing a cathode layer of graphite with expanded inter- planar spaces and that of a cell containing a cathode of original graphite, both plotted as a function of charge/discharge cycles.

FIG. 6 The Ragone plots of three cells: a cell containing a cathode of treated graphite having expanded spaces at the cathode and aluminum thin film supported by a nanostructured network composed of interconnected carbon nanofibers (a porous mat); a cell containing a cathode of treated graphite with expanded inter-planar spaces but no nanostructured mat support; and a cell containing original graphite-based cathode.

FIG. 7 The specific capacity of a cell containing a cathode layer of graphene foam of multi-layer graphene pore walls with expanded inter-planar spaces and that of a cell containing a cathode of graphite foam of pore walls having un-expanded inter-planar spaces, both plotted as a function of charge/discharge cycles.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

As schematically illustrated in the upper portion of FIG. 1(A), bulk natural graphite is a 3-D graphitic material with each graphite particle being composed of multiple grains (a grain being a graphite single crystal or crystallite) with grain boundaries (amorphous or defect zones) demarcating neighboring graphite single crystals. Each grain is composed of multiple graphene planes that are oriented parallel to one another. A graphene plane or hexagonal carbon atom plane in a graphite crystallite is composed of carbon atoms occupying a two-dimensional, hexagonal lattice. In a given grain or single crystal, the graphene planes are stacked and bonded via van der Waal forces in the crystallographic c-direction (perpendicular to the graphene plane or basal plane). The inter-graphene plane spacing in a natural graphite material is approximately 0.3354 nm.

Artificial graphite materials also contain constituent graphene planes, but they have an inter-graphene planar spacing, d ₀ 02, typically from 0.32 nm to 0.36 nm (more typically from 0.3339 to 0.3465 nm), as measured by X-ray diffraction. Many carbon or quasi -graphite materials also contain graphite crystals (also referred to as graphite crystallites, domains, or crystal grains) that are each composed of stacked graphene planes. These include mesocarbon microbeads (MCMBs), mesophase carbon, soft carbon, hard carbon, coke (e.g. needle coke), carbon or graphite fibers (including vapor-grown carbon nanofibers or graphite nanofibers), and multi-walled carbon nanotubes (MW-CNT). The spacing between two graphene rings or walls in a MW-CNT is approximately 0.27 to 0.42 nm. The most common spacing values in MW-CNTs are in the range of 0.32-0.35 nm and do not strongly depend on the synthesis method.

It may be noted that the "soft carbon" refers to a carbon material containing graphite domains wherein the orientation of the hexagonal carbon planes (or graphene planes) in one domain and the orientation in neighboring graphite domains are not too mis-matched from each other so that these domains can be readily merged together when heated to a temperature above 2,000°C (more typically above 2,500°C). Such a heat treatment is commonly referred to as graphitization. Thus, the soft carbon can be defined as a carbonaceous material that can be graphitized. In contrast, a "hard carbon" can be defined as a carbonaceous material that contain highly mis-oriented graphite domains that cannot be thermally merged together to obtain larger domains; i.e. the hard carbon cannot be graphitized. The spacing between constituent graphene planes of a graphite crystallite in a natural graphite, artificial graphite, and other graphitic carbon materials in the above list can be expanded (i.e. the d ₀ 02 spacing being increased from the original range of 0.27- 0.42 nm to the range of 0.42-2.0 nm) using several expansion treatment approaches, including oxidation, fluorination, chlorination, bromination, iodization, nitrogenation, intercalation, combined oxidation-intercalation, combined fluorination-intercalation, combined chlonnation-intercalation, combined bromination-intercalation, combined iodization-intercalation, or combined

nitrogenation -intercalation of the graphite or carbon material.

More specifically, due to the van der Waals forces holding the parallel graphene planes together being relatively weak, natural graphite can be treated so that the spacing between the graphene planes can be increased to provide a marked expansion in the c-axis direction. This results in a graphite material having an expanded spacing, but the laminar character of the hexagonal carbon layers is substantially retained. The inter-planar spacing (also referred to as inter-graphene spacing) of graphite crystallites can be increased (expanded) via several approaches, including oxidation, fluorination, and/or intercalation of graphite. This is

schematically illustrated in FIG. 1(D). The presence of an intercalant, oxygen-containing group, or fluorine-containing group serves to increase the spacing between two graphene planes in a graphite crystallite. This inter-planar spacing may be further increased to become 1.2 nm-2.0 nm if the intercalated, oxidized, or fluorinated graphite is exposed to a moderate temperature (150- 800°C) under a constant-volume condition. This is herein referred to as a constrained expansion treatment.

In one process, graphite materials having an expanded inter-planar spacing are obtained by intercalating natural graphite particles with a strong acid and/or an oxidizing agent to obtain a graphite intercalation compound (GIC) or graphite oxide (GO), as illustrated in FIG. 1(A). The presence of chemical species or functional groups in the interstitial spaces between graphene planes serves to increase the inter-graphene spacing, i¾02, as determined by X-ray diffraction, thereby significantly reducing the van der Waals forces that otherwise hold graphene planes together along the c-axis direction. The GIC or GO is most often produced by immersing natural graphite powder (100 in FIG. 1(A)) in a mixture of sulfuric acid, nitric acid (an oxidizing agent), and another oxidizing agent (e.g. potassium permanganate or sodium perchlorate). The resulting GIC (102) is actually some type of graphite oxide (GO) particles if an oxidizing agent is present during the intercalation procedure. This GIC or GO is then repeatedly washed and rinsed in water to remove excess acids, resulting in a graphite oxide suspension or dispersion, which contains discrete and visually discernible graphite oxide particles dispersed in water.

Water may be removed from the suspension to obtain "expandable graphite," which is essentially a mass of dried GIC or dried graphite oxide particles. The inter-graphene spacing, i¾02, in the dried GIC or graphite oxide particles is typically in the range of 0.42-2.0 nm, more typically in the range of 0.5-1.2 nm. It may be noted than the "expandable graphite" is not "expanded graphite" (to be further explained later).

Upon exposure of expandable graphite to a temperature in the range of typically 800 °C - 1,050°C for approximately 30 seconds to 2 minutes, the GIC undergoes a rapid volume expansion by a factor of 30-300 to form "exfoliated graphite" or "graphite worms" (104),

Graphite worms are each a collection of exfoliated, but largely un-separated graphite flakes that remain interconnected (FIG. 1(B) and FIG. 1(C)). In exfoliated graphite, individual graphite flakes (each containing 1 to several hundred of graphene planes stacked together) are highly spaced from one another, having a spacing of typically 2.0 nm - 200 μπι. However, they remain physically interconnected, forming an accordion or worm-like structure.

In graphite industry, graphite worms can be re-compressed to obtain flexible graphite sheets or foils (106) that typically have a thickness in the range of 0.1 mm (100 μπι) - 0.5 mm (500 μπι). In the instant invention, a cathode active material or its precursor is incorporated into pores of a mass of graphite worms before this mass is re-compressed to form a cathode layer of a desired porosity level or physical density. Alternatively, in graphite industry, one may choose to use a low-intensity air mill or shearing machine to simply break up the graphite worms for the purpose of producing the so- called "expanded graphite" flakes (108) which contain mostly graphite flakes or platelets thicker than 100 nm (hence, not a nano material by definition). It is clear that the "expanded graphite" is not "expandable graphite" and is not "exfoliated graphite worm" either. Rather, the "expandable graphite" can be thermally exfoliated to obtain "graphite worms," which, in turn, can be subjected to mechanical shearing to break up the otherwise interconnected graphite flakes to obtain "expanded graphite" flakes.

Alternatively, the exfoliated graphite or graphite worms may be subjected to high- intensity mechanical shearing (e.g. using an ultrasonicator, high-shear mixer, high-intensity air jet mill, or high-energy ball mill) to form separated single-layer and multi -layer graphene sheets (collectively called NGPs, 112), as disclosed in our US Application No. 20050271574,

(December 8, 2005). Single-layer graphene can be as thin as 0.34 nm, while multi-layer graphene can have a thickness up to 100 nm, but more typically less than 3 nm (commonly referred to as few-layer graphene). Multiple graphene sheets or platelets may be made into a sheet of NGP paper (114) using a paper-making process.

In GIC or graphite oxide, the inter-graphene plane separation has been increased from 0.3354 nm in natural graphite to 0.5-1.2 nm in highly oxidized graphite oxide, significantly weakening the van der Waals forces that hold neighboring planes together. Graphite oxide can have an oxygen content of 2%-50% by weight, more typically 20%-40% by weight. GIC or graphite oxide may be subjected to a special treatment herein referred to as "constrained thermal expansion". If GIC or graphite oxide is exposed to a thermal shock in a furnace (e.g. at 800 - 1,050°C) and allowed to freely expand, the final product is exfoliated graphite worms. However, if the mass of GIC or graphite oxide is subjected to a constrained condition (e.g. being confined in an autoclave under a constant volume condition or under a uniaxial compression in a mold) while being heated at a temperature from 150°C to 800°C (more typically from 300°C to 600°), the extent of expansion can be constrained and the product can have inter-planar spaces from 1.0 nm to 3.0 nm, or from 1.2 nm to 2.0 nm. It may be noted that the "expandable graphite" or graphite with expanded inter-planar spacing may also be obtained by forming graphite fluoride (GF), instead of GO. Interaction of F ₂ with graphite in a fluorine gas at high temperature leads to covalent graphite fluorides, from (CF)„ to (C ₂ F)„, while at low temperatures graphite intercalation compounds (GIC) C _X F (2 < x < 24) form. In (CF)„ carbon atoms are sp3 -hybridized and thus the fluorocarbon layers are corrugated consisting of trans-linked cyclohexane chairs. In (C ₂ F)„ only half of the C atoms are fluorinated and every pair of the adjacent carbon sheets are linked together by covalent C-C bonds. Systematic studies on the fluorination reaction showed that the resulting F/C ratio is largely dependent on the fluorination temperature, the partial pressure of the fluorine in the fluorinating gas, and physical characteristics of the graphite precursor, including the degree of graphitization, particle size, and specific surface area. In addition to fluorine (F ₂ ), other fluorinating agents (e.g. mixtures of F ₂ with Br ₂ , Cl ₂ , or I ₂ ) may be used, although most of the available literature involves fluorination with F ₂ gas, sometimes in presence of fluorides.

We have observed that lightly fluorinated graphite, C _X F (2 < x < 24), obtained from electrochemical fluorination, typically has an inter-graphene spacing (d ₀ o ₂ ) less than 0.37 nm, more typically < 0.35 nm. Only when x in C _X F is less than 2 (i.e. 0.5 < x < 2) can one observe a doo ₂ spacing greater than 0.5 nm (in fluorinated graphite produced by a gaseous phase fluorination or chemical fluorination procedure). When x in C _X F is less than 1.33 (i.e. 0.5 < x < 1.33) one can observe a d ₀ o ₂ spacing greater than 0.6 nm. This heavily fluorinated graphite is obtained by fluorination at a high temperature (» 200°C) for a sufficiently long time, preferably under a pressure > 1 atm, and more preferably > 3 atm. For reasons remaining unclear, electrochemical fluorination of graphite leads to a product having a d spacing less than 0.4 nm even though the product C _X F has an x value from 1 to 2. It is possible that F atoms

electrochemically introduced into graphite tend to reside in defects, such as grain boundaries, instead of between graphene planes and, consequently, do not act to expand the inter-graphene planar spacing..

The nitrogenation of graphite can be conducted by exposing a graphite oxide material to ammonia at high temperatures (200-400°C). Nitrogenation may also be conducted at lower temperatures by a hydrothermal method; e.g. by sealing GO and ammonia in an autoclave and then increased the temperature to 150-250°C.

In addition to N, O, F, Br, CI, or H, the presence of other chemical species (e.g. Na, Li, K, Ce, Ca, Fe, H ₄ , etc.) between graphene planes can also serve to expand the inter-planar spacing, creating room to accommodate electrochemically active materials therein. The expanded interstitial spaces between graphene planes (hexagonal carbon planes or basal planes) are found by us in this study to be surprisingly capable of accommodating Al ⁺³ ions and other anions (derived from electrolyte ingredients) as well. It may be noted that graphite can electrochemically intercalated with such chemical species as Na, Li, K, Ce, Ca, NH ₄ , or their combinations, which can then be chemically or electrochemically ion-exchanged with metal elements (Bi, Fe, Co, Mn, Ni, Cu, etc.). All these chemical species can serve to expand the inter- planar spacing.

The configuration of an aluminum secondary battery is now discussed as follows:

An aluminum secondary battery includes a positive electrode (cathode), a negative electrode (anode), and an electrolyte including an aluminum salt and a solvent. The anode can be a thin foil or film of aluminum metal or aluminum metal alloy. The anode can be composed of particles, fibers, wires, tubes, or discs of Al metal or Al metal alloy that are packed and bonded together by a binder (preferably a conductive binder) to form an anode layer.

A desirable anode layer structure is composed of a network of electron-conducting pathways (e.g. mat of graphene sheets, carbon nanofibers, or carbon-nanotubes) and a thin layer of aluminum metal or alloy coating deposited on surfaces of this conductive network structure. Such an integrated nanostructure may be composed of electrically conductive nanometer-scaled filaments that are interconnected to form a porous network of electron-conducting paths comprising interconnected pores, wherein the filaments have a transverse dimension less than 500 nm. Such filaments may comprise an electrically conductive material selected from the group consisting of electrospun nano fibers, vapor-grown carbon or graphite nano fibers, carbon or graphite whiskers, carbon nanotubes, nanoscaled graphene platelets, metal nano wires, and combinations thereof. Such a nanostructured, porous supporting material for aluminum can significantly improve the aluminum deposition-dissolution kinetics, enabling high-rate capability of the resulting aluminum secondary cell.

Illustrated in FIG. 2(A) is a schematic of an aluminum secondary battery, wherein the anode layer is a thin Al coating or Al foil and the cathode active material layer contains a layer of graphite foam or graphene foam wherein the pore walls contain multiple hexagonal carbon atom planes bonded together having expanded inter-planar spaces (doo ₂ = 0.4 nm to 2.0 nm). Alternatively, FIG. 2(B) shows a schematic of an aluminum secondary battery cell wherein the cathode active material layer is composed of particles or fibers of a graphite or carbon material (having expanded inter-planar spaces), a conductive additive (not shown), and a resin binder (not shown) that helps to bond the particles or fibers together to form a cathode active layer of structural integrity.

The composition of the electrolyte, which functions as an ion-transporting medium for charge-discharge reaction, has a great effect on battery performance. To put aluminum secondary batteries to practical use, it is necessary to allow aluminum deposition-dissolution reaction to proceed smoothly and sufficiently even at relatively low temperature (e.g., room temperature). In conventional aluminum secondary batteries, however, aluminum deposition-dissolution reaction can proceed smoothly and sufficiently only at relatively high temperature (e.g., 50°C or higher), and the efficiency of the reaction is also low. The electrolyte for use in an aluminum secondary battery can include an aluminum salt, alkyl sulfone, and a solvent with a dielectric constant of 20 or less so that the electrolyte can operate at a lower temperature (e.g. room temperature) at which aluminum deposition-dissolution reaction proceeds.

Aqueous electrolytes that can be used in the aluminum secondary batteries include aluminum salts dissolved in water; for instance, A1C1 ₃ -6H ₂ 0, CrCl ₃ -6H ₂ 0, and A1(N03) ₃ in water. Alkaline solutions, such as KOH and NaOH in water, may also be used.

Organic electrolytes for use in aluminum secondary batteries include various electrolytes with g-butyrolactone (BLA) or acetonitrile (ACN) as solvent; e.g. A1C1 ₃ /KC1 salts in BLA or (C ₂ H ₅ ) ₄ NClxH ₂ 0 (TEAC) in ACN. Also included are concentrated aluminum triflate-based electrolyte, a bath of aluminum chloride and lithium aluminum hydride dissolved in diethyl ether, and LiAlH ₄ and AICI ₃ in tetrahydrofuran. For example, alkyl sulfone such as dimethyl sulfone may be used, along with an organic solvent such as a cyclic or chain carbonate or a cyclic or chain ether can be used. In order to reduce polarization during discharge, an aluminum salt such as aluminum chloride and an organic halide such as

trimethylphenylammonium chloride may be used together in the electrolyte. For this salt mixture, an organic solvent such as 1,2-dichloroethane may be used.

Another type of electrolyte capable of reversible aluminum electrochemistry is molten salt eutectics. These are typically composed of aluminum chloride, sodium chloride, potassium chloride and lithium chloride in some molar ratio. Useful molten salt electrolytes include AICI ₃ - NaCl, AlCl ₃ -(LiCl-KCl), and A1C1 ₃ - KC1 - NaCl mixtures. Among these alkali chloroaluminate melts, binary NaCl-AlCl ₃ and ternary NaCl-KCl-AlCl ₃ systems are the most widely used molten salts for developing aluminum batteries. In these systems the melts with molar ratio of MCI/AICI ₃ (where M is commonly Na and/or K) larger than unity are defined as basic, whereas those with molar ratio less than unity as acidic. In an acidic melt, AI ₂ CI ₇ is the major anion species. As the acidity (A1C1 ₃ content) of the melt decreases, A1C1 ₄ ^" becomes the major species.

A special class of molten salt for use in an aluminum secondary battery is room temperature molten salts (ionic liquids). For instance, a useful ionic liquid electrolyte solution is aluminum chloride mixed in l-ethyl-3-methylimidazolium chloride (AlC^iEMIC).

Commercially available l-ethyl-3-methylimidazolium chloride may be purified by

recrystallization from ethyl acetate and acetonitrile. Aluminum chloride may be further purified by triple sublimation. The ionic liquid may be prepared by slowly mixing molar equivalent amounts of both salts. Further, AICI ₃ was then added to the equimolar mix until a concentration of 1M AICI ₃ was obtained. Desirably, this concentration corresponds to a molar ratio of 1.2: 1, A1C1 ₃ :EMIC. Aluminum chloride (AICI ₃ ) also forms room temperature electrolytes with organic chlorides, such as n-butyl-pyridinium-chloride (BuPyCl), l-methyl-3-ethylimidazolium-chloride (MEIC1), and 2-dimethyl-3-propylimidazolium-chloride. The molten mixture of 1,4-dimethyl- 1,2,4-triazolium chloride (DMTC) and A1C1 ₃ may also be used as the secondary battery electrolyte.

This invention is directed at the cathode active layer (positive electrode layer) containing a high-capacity cathode material for the aluminum secondary battery. The invention also provides such a battery based on an aqueous electrolyte, a non-aqueous electrolyte, a molten salt electrolyte, a polymer gel electrolyte (e.g. containing an aluminum salt, a liquid, and a polymer dissolved in the liquid), or an ionic liquid electrolyte. The shape of an aluminum secondary battery can be cylindrical, square, button-like, etc. The present invention is not limited to any battery shape or configuration.

The following examples are used to illustrate some specific details about the best modes of practicing the instant invention and should not be construed as limiting the scope of the invention.

Example 1: Oxidation of graphite

Natural flake graphite, nominally sized at 45 μπι, provided by Asbury Carbons (405 Old Main St., Asbury, N.J. 08802, USA) was milled to reduce the size to approximately 14 μπι (Sample la). The chemicals used in the present study, including fuming nitric acid (>90%), sulfuric acid (95-98%), potassium chlorate (98%>), and hydrochloric acid (37%>), were purchased from Sigma-Aldrich and used as received. Graphite oxide (GO) samples were prepared according to the following procedure:

Sample 1 A: A reaction flask containing a magnetic stir bar was charged with sulfuric acid (176 mL) and nitric acid (90 mL) and cooled by immersion in an ice bath. The acid mixture was stirred and allowed to cool for 15 min, and graphite (10 g) was added under vigorous stirring to avoid agglomeration. After the graphite powder was well dispersed, potassium chlorate (110 g) was added slowly over 15 min to avoid sudden increases in temperature. The reaction flask was loosely capped to allow evolution of gas from the reaction mixture, which was stirred for 24 hours at room temperature. On completion of the reaction, the mixture was poured into 8 L of deionized water and filtered. The GO was re-dispersed and washed in a 5%> solution of HC1 to remove sulfate ions. The filtrate was tested intermittently with barium chloride to determine if sulfate ions are present. The HCl washing step was repeated until this test was negative. The GO was then washed repeatedly with deionized water until the pH of the filtrate was neutral. The GO slurry was spray-dried and stored in a vacuum oven at 60°C until use.

Sample IB: The same procedure as in Sample 1 A was followed, but the reaction time was 48 hours.

Sample 1C: The same procedure as in Sample 1 A was followed, but the reaction time was 96 hours.

X-ray diffraction studies showed that after a treatment of 24 hours, a significant proportion of graphite has been transformed into graphite oxide. The peak at 2Θ =26.3 degrees, corresponding to an inter-planar spacing of 0.335 nm (3.35 A) for pristine natural graphite was significantly reduced in intensity after a deep oxidation treatment for 24 hours and a peak typically near 2Θ = 9-14 degrees (depending upon degree of oxidation) appeared. In the present study, the curves for treatment times of 48 and 96 hours are essentially identical, showing that essentially all of the graphite crystals have been converted into graphite oxide with an inter- planar spacing of 6.5-7.5 A (the 26.3 degree peak has totally disappeared and a peak of approximately at 2Θ = 11.75-13.7 degrees appeared).

Example 2: Oxidation and intercalation of various graphitic carbon and graphite materials

Samples 2A, 2B, 2C, and 2D were prepared according to the same procedure used for Sample IB, but the starting graphite materials were pieces of highly oriented pyrolytic graphite (HOPG), graphite fiber, graphitic carbon nanofiber, and spheroidal graphite, respectively. Their final inter-planar spacings are 6.6 A, 7.3 A, 7.3 A, and 6.6 A, respectively. Their un-treated counterparts are referred to as Sample 2a, 2b, 2c, and 2d, respectively.

Example 3: Preparation of graphite oxide using a modified Hummers' method

Graphite oxide (Sample 3 A) was prepared by oxidation of natural graphite flakes (original size of 200 mesh, from Huadong Graphite Co., Pingdu, China, milled to approximately 15 .mu.m, referred to as Sample 3a) with sulfuric acid, sodium nitrate, and potassium

permanganate according to the method of Hummers [U.S. Pat. No. 2,798,878, Jul. 9, 1957]. In this example, for every 1 gram of graphite, we used a mixture of 22 ml of concentrated sulfuric acid, 2.8 grams of potassium permanganate, and 0.5 grams of sodium nitrate. The graphite flakes were immersed in the mixture solution and the reaction time was approximately one hour at 35. degree. C. It is important to caution that potassium permanganate should be gradually added to sulfuric acid in a well-controlled manner to avoid overheat and other safety issues. Upon completion of the reaction, the mixture was poured into deionized water and filtered. The sample was then washed repeatedly with deionized water until the pH of the filtrate was approximately 5. The slurry was spray-dried and stored in a vacuum oven at 60°C for 24 hours. The interlay er spacing of the resulting laminar graphite oxide was determined by the Debye-Scherrer X-ray technique to be approximately 0.73 nm (7.3 A).

Example 4: Oxidation of mesocarbon microbeads (MCMBs)

Graphite oxide (Sample 4 A) was prepared by oxidation of mesocarbon microbeads

(MCMBs) according to the same procedure used in Example 3. MCMB 2528 microbeads (Sample 4a) were supplied by Alumina Trading, which is the U.S. distributor for the supplier, Osaka Gas Company of Japan. This material has a density of about 2.24 g/cm ³ ; a particle size maximum for at least 95% by weight of the particles of 37 microns; median size of about 22.5 microns and an inter-planar distance of about 0.336 nm. After deep oxidation treatment, the inter-planar spacing in the resulting graphite oxide microbeads is approximately 0.76 nm.

Example 5: Bromination and fluorination of carbon fibers

Graphitized carbon fiber (Sample 5a), having an inter-planar spacing of 3.37 A (0.337 nm) and a fiber diameter of 10 μπι was first halogenated with a combination of bromine and iodine at temperatures ranging from 75°C to 115°C to form a bromine-iodine intercalation compound of graphite as an intermediate product. The intermediate product was then reacted with fluorine gas at temperatures ranging from 275°C to 450°C to form the CF _y . The value of y in the CF _y samples was approximately 0.6-0.9. X-ray diffraction curves typically show the coexistence of two peaks corresponding to 0.59 nm and 0.88 nm, respectively. Sample 5A exhibits substantially 0.59 nm peak only and Sample 5B exhibits substantially 0.88 nm peak only.

Example 6: Fluorination of carbon fibers

A CFo.68 sample obtained in EXAMPLE 5 was exposed at 250°C and 1 atmosphere to vapors of l,4-dibromo-2-butene (BrH ₂ C— CH=.CH~CH ₂ Br) for 3 hours. It was found that two- thirds of the fluorine was lost from the graphite fluoride sample. It is speculated that 1,4- dibromo-2-butene actively reacts with graphite fluoride, removing fluorine from the graphite fluoride and forming bonds to carbon atoms in the graphite lattice. The resulting product (Sample 6A) is mixed halogenated graphite, likely a combination of graphite fluoride and graphite bromide.

Example 7: Fluorination of graphite

Natural graphite flakes, a sieve size of 200 to 250 mesh, were heated in vacuum (under less than 10 ^"2 mmHg) for about 2 hours to remove the residual moisture contained in the graphite. Fluorine gas was introduced into a reactor and the reaction was allowed to proceed at 375°C for 120 hours while maintaining the fluorine pressure at 200 mmHg. This was based on the procedure suggested by Watanabe, et al. disclosed in U.S. Pat. No. 4, 139,474. The powder product obtained was black in color. The fluorine content of the product was measured as follows: The product was burnt according to the oxygen flask combustion method and the fluorine was absorbed into water as hydrogen fluoride. The amount of fluorine was determined by employing a fluorine ion electrode. From the result, we obtained a GF (Sample 7A) having an empirical formula (CF ₀ .75) _n - X-ray diffraction indicated a major (002) peak at 2Θ =13.5 degrees, corresponding to an inter-planar spacing of 6.25 A.

Sample 7B was obtained in a manner similar to that for Sample 7A, but at a reaction temperature of 640°C for 5 hours. The chemical composition was determined to be (CF ₀ .93) _n - X- ray diffraction indicated a major (002) peak at 2Θ =9.5 degrees, corresponding to an inter-planar spacing of 9.2 A.

Example 8: Preparation of carbon-coated GO particles

Two polymeric carbon-coated GO samples (Samples 8-A and 8-B) were prepared by mixing GO particles (prepared in Example 3 and Example 4, respectively) with a phenol resin to obtain a mixture comprising 20% by volume of phenol resin in each case. The mixture was cured at 200°C for one hour and then carbonized in an argon atmosphere at a temperature of 500°C under a constant-volume condition. Then, the carbonized product was ground and milled to obtain particles of 1 to 23 μιτι, with an average diameter of approximately 13 μιη. The inter- planar spacing was determined to be approximately 0.73 nm and 0.76 nm, respectively, prior to the constrained expansion treatment. After this constrained expansion treatment, the d spacing of the GO particles was increased to 1.27 nm and 1.48 nm, respectively (Samples 8-C and 8-D.

Example 9: Preparation of carbon-coated GF particles

Natural flake graphite, milled to an average size of approximately 14 microns, was subjected to the same fluorination treatment as described in Example 7 and determined to be (CF ₀ .75)n (Sample 7B). The resulting powder was subjected to a chemical vapor deposition (CVD) of amorphous carbon according to a procedure suggested by Tanaka, et al., U.S. Pat. No. 5,344,726. A (CF ₀ .75) _n sample powder of 50 mg was placed in a quartz tube reactor, and then argon gas and propane gas were supplied from an argon supply line and a propane supply line, respectively. Then, a propane concentration of raw gas was set to 10 mole % by handling needle valves. Flow velocity of the raw gas was set to 12.7 cm/min and an amount of supply of propane was set to 0.05 mol/h. It may be noted that a hydrocarbon or its derivatives other than propane may be used as a raw material. More specifically, an aliphatic hydrocarbon, an aromatic hydrocarbon, an alicyclic hydrocarbon or the like may be used. Further specifically, methane, ethane, butane, benzene, toluene, naphthalene, acetylene, biphenyl and substitution products thereof may be used. The powder was heated by a furnace at approximately 750°C under a constant-volume condition, whereby propane supplied from a pyrex tube was pyrolytically decomposed with a pyrolysis carbon being deposited on the surface of the graphite fluoride powder. The resulting material was milled to become fine particles of approximately 16.5 microns, which are essentially amorphous carbon-coated GF particles (Sample 9B).

Example 10: Preparation of graphene foam having pore walls with expanded inter-planar spaces

In one sample, five grams of the graphite oxide were mixed with 2,000 ml alcohol solution consisting of alcohol and distilled water with a ratio of 15:85 to obtain a slurry mass. Then, the mixture slurry was subjected to ultrasonic irradiation with a power of 200 W for various lengths of time. After 20 minutes of sonication, GO fibers were effectively exfoliated and separated into thin graphene oxide sheets with oxygen content of approximately 23%-31% by weight. The resulting suspension contains GO sheets being suspended in water. A chemical blowing agent (hydrazo dicarbonamide) was added to the suspension just prior to casting. The resulting suspension was then cast onto a glass surface using a doctor's blade to exert shear stresses, inducing GO sheet orientations. The resulting GO coating films, after removal of liquid, have a thickness that can be varied from approximately 5 to 500 μπι (preferably and typically from 10 μπι to 50 μπι).

For making a graphene foam specimen, the GO coating film was then subjected to heat treatments that typically involve an initial thermal reduction temperature of 80-350°C for 1-8 hours, followed by heat-treating at a second temperature of 1,500-2,850°C for 0.5 to 5 hours.

Several pieces of GO-derived graphene foam were subsequently subjected to oxidation treatment to produce GO foam containing graphene pore walls having expanded inter-planar spaces.

Example 11: Preparation of graphite foam having pore walls with expanded inter-planar spaces Pitch powder, granules, or pellets were placed in a aluminum mold with the desired final shape of the foam. Mitsubishi ARA-24 mesophase pitch was utilized. The sample was evacuated to less than 1 torr and then heated to a temperature approximately 300°C. At this point, the vacuum was released to a nitrogen blanket and a pressure of up to 1,000 psi was applied. The temperature of the system was then raised to 800°C. This was performed at a rate of 2 degree C/min. The temperature was held for at least 15 minutes to achieve a soak and then the furnace power was turned off and cooled to room temperature at a rate of approximately 1.5 degree C/min with release of pressure at a rate of approximately 2 psi/min. Final foam temperatures were 630°C and 800°C. During the cooling cycle, pressure is released gradually to atmospheric conditions. The foam was then heat treated to 1050°C (carbonized) under a nitrogen blanket and then heat treated in separate runs in a graphite crucible to 2500°C and 2800°C (graphitized) in Argon.

Several pieces of graphite foam were subjected to fluorination to obtain graphite fluoride foam according to the procedure used in Example 7.

Example 12: Preparation and testing of various aluminum cells

The particles or fibers of carbon or graphite materials prepared in Examples 1-8 were separately made into a cathode layer and incorporated into an aluminum secondary battery. The cathode layer was prepared in the following way. First of all, 95% by weight of the carbon or graphite powder having expanded inter-planar spaces were mixed together with PVDF (a binder) in MP to obtain a slurry mixture. The slurry mixture was then cast onto a glass surface to make a wet layer, which was dried to obtain a cathode layer. Layers of graphite foam or graphene foam were directly used as a cathode active layer.

Two types of Al anode were prepared. One was Al foil having a thickness from 16 μιη to

300 μιη. The other was Al thin coating deposited on surfaces of conductive nanofilaments (e.g. CNTs) or graphene sheets that form an integrated 3D network of electron-conducting pathways having pores and pore walls to accept Al or Al alloy. Either the Al foil itself or the integrated 3D nanostructure also serves as the anode current collector.

Cyclic voltammetry (CV) measurements were carried out using an Arbin electrochemical workstation at a typical scanning rate of 0.5-50 mV/s. In addition, the electrochemical performances of various cells were also evaluated by galvanostatic charge/discharge cycling at a current density from 50 mA/g to 10 A/g. For long-term cycling tests, multi-channel battery testers manufactured by LAND were used.

FIG. 3 shows the charge and discharge curves of two Al foil anode-based cells each having a graphite foam-based cathode (one with expanded inter-planar spaces and one without). The electrolyte used was aluminum chloride mixed in l-ethyl-3-methylimidazolium chloride (A1C1 ₃ :EMIC molar ratio = 2/1 to 3.5/1). These data indicate that the two battery cells deliver comparable cell voltage, but the presently invented cathode layer featuring graphite foam containing pore walls having expanded inter-planar spacing has a significantly higher specific capacity (290 mAh/g) as compared to the cathode featuring original graphite foam material (65 mAh/g).

The charge or discharge curve of the invented cathode layer is characterized by having three regimes, likely corresponding to three charge storage mechanisms. These three regimes each cover a large specific capacity range. Not wishing to be bound by theory, but we believe that the three mechanisms at the cathode during battery charging are (1) desorption of ΕΜΓ ^" ions from graphite surfaces, (2) de-intercalation by Al ³⁺ from the inter-planar spaces, and (3) intercalation of inter-planar spaces in graphite by A1C1 ₄ ^" anions and/or adsorption of A1C1 ₄ ^" anions near graphite surfaces. At the anode, during battery charging, AI2CI7 ^" ions react with electrons to form AICI4 ^" anions and Al, wherein AICI4 ^" anions move toward the cathode and Al deposits on Al foil or surface of the anode current collector. The Al ³⁺ ions released from the cathode may also react with electrons to form Al metal atoms that re-deposit onto Al foil surface or the surface of an anode current collector. Some EMI ⁺ ions may form electric double layers near the anode surfaces. The above processes are reversed when the battery is discharged.

In contrast, the charge or discharge curve of the conventional graphite foam-based cathode layer only shows two regimes that are also much shorter, corresponding to two charge storage mechanisms. It is clear that by expanding the inter-planar spacing, one opens up other energy storage opportunities. This is truly unexpected and has great utility value.

FIG. 4 show the specific capacity values of a wide variety of carbon or graphite materials plotted as a function of the inter-planar spacing. The carbon or graphite material types, their respective inter-planar spacing values and specific capacity values when used as an Al cell cathode active material are summarized in Table 1 below:

Table 1 : A list of carbon or graphite materials used as the cathode active material of an Al cell.

Inter-planar Specific capacity,

Sample No. Material spacing, A mAh/g

la Natural graphite 3.35 65

1A GO, 24 hrs 5.5 205

IB GO, 48 hrs 7 278

1C GO, 96 hrs 7.6 305

2a HOPG 3.35 67

2A HOPG oxide 6.6 226

2b Graphite fiber 3.4 59

2B Oxidized GF 7.3 205

2c CNF 3.36 76

2C Oxidized CNF 7.3 292

2d Spheroidal Gr 3.35 63

2D Oxidized S-Gr 7.5 267

3a Natural graphite 3.35 66

3A GO, Hummers 7.3 322

4a MCMB 3.36 73

4A Oxidized MCMB 7.6 326

5a Graphite fiber 3.4 62

6A CBrF _x 8.4 393

8A 3A+C-coated 7.3 288

8B 4A+C-coated 7.6 293

8C Constrained expansion 12.7 510

8D Constrained expansion 14.8 566

9A 7A+CVD-C 9 423

10A PANi-bonded 7.3 283

The following significant observations are made from Table 1 and related charts (FIG. 4- FIG. 7):

(1) In every group of carbon or graphite material used in the cathode of an aluminum battery, the specific capacity of the cathode materials with expanded interstitial spaces (inter- planar spacing greater 0.45 nm or 4.5 A) are significantly higher than those of their un-expanded counterparts. For instance, 1A, IB, 1C, and ID (graphite oxide) are all greater than la (natural graphite).

(2) The total specific capacity (FIG. 4) increases with increasing inter-planar spacing when all the data points for Samples 1-10 are plotted on the same chart (regardless the type of carbon or graphite materials). Hence, it is fair to say that the present invention provides a powerful platform technology for enhancing the specific capacity of carbon or graphite cathode materials.

(3) The data for Samples 8C, and 8D demonstrate that a constrained expansion of an intercalated or fluorinated/oxidized carbon/graphite material can further expand the interstitial spaces, leading to a significantly higher charge storage capacity.

(4) As demonstrated in FIG. 5, the treated graphite material with expanded interstitial spaces is also more capable of retaining the specific capacity as the secondary battery undergoes cycles of charge and discharge. It is speculated that the associated treatment has provided a stable inter-planar spaces that do not collapse due to repeated intercalation/de-intercalation cycles of the battery. Those who are skilled in the art would have predicted that the expanded interstitial spaces favor the co-intercalation of solvents, which has been one of the primary causes of capacity fade. To the contrary and quite surprisingly, the expanded interstitial spaces (with an inter-planar spacing up to 14.8 A) did not seem to have any solvent co-intercalation- induced capacity decay issue.

(5) FIG. 6 shows the Ragone plots of three cells: a cell containing a cathode of treated graphite having expanded spaces at the cathode and aluminum thin film supported by a nanostructured network composed of interconnected carbon nanofibers; a cell containing a cathode of treated graphite with expanded inter-planar spaces but no nanostructured mat support; and a cell containing original graphite-based cathode. This nanostructured network of interconnected carbon nanofibers provides large surface areas to support aluminum and facilitate fast and uniform dissolution and deposition of aluminum cations at the anode side. Other nanofilaments or nanostructures that can be used to make such a network include electrospun nano fibers, vapor-grown carbon or graphite nano fibers, carbon or graphite whiskers, carbon nanotubes, nanoscaled graphene platelets, metal nano wires, or a combination thereof.

(6) FIG. 7 shows the specific capacity of a cell containing a cathode layer of graphene foam of multi-layer graphene-based pore walls with expanded inter-planar spaces and that of a cell containing a cathode of graphite foam of pore walls having un-expanded inter-planar spaces, both being plotted as a function of charge/discharge cycles. Clearly, the graphene foam having expanded inter-graphene planar spacing delivers not only a higher energy density, but also a more stable cycling behavior (up to 8,000 cycles without any significant capacity decay). The presently invented aluminum cells exhibit some supercapacitor-like behavior (having long cycle life) and some lithium ion battery-like behavior (moderate energy density).